EP4665519A2 - Vehicle member assembly and method for manufacturing the same - Google Patents

Abstract

A vehicle member assembly comprises a closed cross-section beam portion, and at least one open-section beam portion. Trim edge laser weld joints connect a pair of opposing, spaced legs of the open-section beam portion to opposite sides of the closed cross-section beam portion. Another vehicle member assembly comprises a single metal sheet roll formed to form two adjacent beam portions. For each of the beam portions, a second side wall (a) contacts and overlaps a first side wall of the other of the beam portions, and (b) has a terminal edge terminating at a location along the first side wall of the other of the beam portions. A trim edge laser weld joint connects the terminal edge of each of the second side walls to the contacted first side wall of the other beam portion at the location along the first side wall.

Description

VEHICLE MEMBER ASSEMBLY AND METHOD FOR MANUFACTURING THE SAME

BACKGROUND

Cross Reference to Related Applications

[0001] This application claims priority of U.S. Provisional Application No. 63/446,551 filed February 17, 2023, which is incorporated herein in its entirety by reference.

Field

[0002] The present patent application relates to a vehicle member assembly and a method for manufacturing the same.

Description of Related Art

[0003] It is known to galvanize or apply protective zinc coatings to steel components of a vehicle to prevent rust or iron oxide from forming on the steel components over time. For example, in an electric truck rocker assembly that has stringent safety requirement to meet side pole regulatory requirements and that has a complicated closed roll form section with lap weld(s), a galvanic coating/material may be used. It is also generally known that welding galvanized metal creates zinc oxide fumes when the zinc layer or coating is burned off or evaporated from the steel component at or near the weld joint from the high heat used in some forms of welding (such as laser lap welding). The zinc oxide fumes generated during welding should be ventilated from an area surrounding the weld joint. Specifically, if these zinc oxide gases are not vented properly, the zinc oxide gases get trapped, for example, in between the lap weld surfaces of two mating components. Entrapped zinc oxide gases may cause poor weld quality such as gas inclusions, blow holes, pin holes, poor or no weld penetration, etc.

[0004] U.S. Patent No.: 11,427,144 (“the ’ 144 Patent”) discloses a galvanized beam 10 that may be generally continuously formed with a roll forming process. The ’ 144 Patent includes a method of continuously welding a seam or seams of the galvanized beam 10 closed in a manner that ventilates zinc oxide fumes generated within enclosed areas of the beam 10 (when welding the galvanized sheet stock used to form the galvanized beam 10). That is, referring to FIG. 2 of the ’ 144 Patent, the galvanized multi-tubular beam 10 for a vehicle structure or a bumper reinforcement is manufactured by roll forming a galvanized metal sheet to form two adjacent tubular portions 14, 16 that share a common center wall 18 of the beam 10. The outer sections of the metal sheet that form the two adjacent tubular portions 14, 16 extend from opposing sides of a center section of the metal sheet that forms the common center wall 18 of the beam 10. Laser welded lap joints 36, 38 are formed to enclose interior areas of the respective adjacent tubular portions 14, 16 of the beam 10. Protrusions 32 are formed at an upper surface of the sheet stock, which is then roll formed to form a tubular shape with the protrusions abutting a surface of the sheet stock to form venting gaps. Zinc oxide gas generated from the welding is permitted to escape an interior of the tubular shape through these venting gaps. The galvanized beam 10 of the ’ 144 Patent is also shown in FIG. 13 of this patent application, which is labeled as “prior art”.

[0005] When different closed sections formed with the laser lap weld(s) and with galvanic coated steel components were studied in detail, all options required additional processes that are in addition to the roll forming process. This is because of the galvanic coating on the steel components. These additional operations/processes/procedures may include scarfing to remove the galvanized coating, adding protrusions that aid in venting the generated Zinc oxide, etc.

[0006] Also, another concern with the laser lap welding is in process quality confirmation check feasibilities. For example, checking the weld quality of the laser lap weld can be feasible only by destructive testing such as cutting and etching.

[0007] Further, closed form single piece roll form generally has manufacturing feasibility challenges due to its complex shape, due to its smaller section dimensions and due to use of martensite material. The martensite material exhibits high spring back during roll form process. It may be challenging to run without frequent production stoppage to ensure no weld gap or tune weld gaps.

[0008] The present patent application endeavors to provide various improvements over known vehicle member assemblies.

SUMMARY

[0009] In one embodiment of the present patent application, a vehicle member assembly is provided. The vehicle member assembly comprises a closed cross-section beam portion, at least one open-section beam portion, and trim edge laser weld joints. The closed cross-section beam portion comprises steel. The open-section beam portion comprises steel. At least one open-section beam portion has a generally U-shaped configuration. The open-section beam portion has a pair of opposing, spaced legs. The trim edge laser weld joints connect the pair of legs of the open-section beam portion to opposite sides of the closed cross-section beam portion. The connected closed-section beam portion and open-section beam portion provide the vehicle member assembly that comprises a pair of generally hollow longitudinal regions separated by a wall portion of the closed cross-section beam portion.

[0010] In another embodiment of the present patent application, a method for forming a vehicle member assembly is provided. The method comprises a method of forming a vehicle member assembly. The method comprises roll forming a closed cross-section beam portion, the closed cross-section beam portion comprising steel; roll forming at least one open-section beam portion having a generally U-shaped configuration, the open-section beam portion having a pair of opposing, spaced legs, the open-section beam portion comprising steel; and connecting the pair of legs of the open-section beam portion to opposite sides of the closed cross-section beam portion by trim edge laser welding. The connected closed-section beam portion and opensection beam portion providing the vehicle member assembly comprising a pair of generally hollow longitudinal regions separated by a wall portion of the closed cross-section beam portion.

[0011] In yet another embodiment of the present patent application, a vehicle member assembly is provided. The vehicle member assembly comprises a single metal sheet roll formed to form two adjacent beam portions, the two adjacent beam portions providing the vehicle member assembly with a pair of generally hollow longitudinal regions separated by a common central wall portion, the common central wall portion having bends at opposite ends thereof transitioning into a pair of first side walls, each first side wall constituting one wall for a respective one of the beam portions, each beam portion having an opposing second side wall being opposite the first side wall. For each of the beam portions, the second side wall (a) contacts and overlaps the first side wall of the other of the beam portions, and (b) has a terminal edge terminating at a location along the first side wall of the other of the beam portions; and a trim edge laser weld joint connecting the terminal edge of each of the second side walls to the contacted first side wall of the other beam portion at the location along the first side wall.

[0012] In yet another embodiment of the present patent application, a method of forming a vehicle member assembly. The method comprises roll forming a single metal sheet to form two adjacent beam portions, the two adjacent beam portions providing the vehicle member assembly with a pair of generally hollow longitudinal regions separated by a common central wall portion, the common central wall portion having bends at opposite ends thereof transitioning into a pair of first side walls, each first side wall constituting one wall for a respective one of the beam portions, each beam portion having an opposing second side wall being opposite the first side wall. For each of the beam portions, the second side wall (a) contacts and overlaps the first side wall of the other of the beam portions, and (b) has a terminal edge terminating at a location along the first side wall of the other of the beam portions. The method also includes connecting by trim edge welding, the terminal edge of each of the second side walls to the contacted first side wall of the other beam portion at the location along the first side wall.

[0013] These and other aspects of the present patent application, as well as the methods of operation and functions of the related elements of structure and the combination of parts and economies of manufacture, will become more apparent upon consideration of the following description with reference to the accompanying drawings, all of which form a part of this specification, wherein like reference numerals designate corresponding parts in the various figures. In one embodiment of the present patent application, the structural components illustrated herein are drawn to scale. It is to be expressly understood, however, that the drawings are for the purpose of illustration and description only and are not intended as a definition of the limits of the present patent application. It shall also be appreciated that the features of one embodiment disclosed herein can be used in other embodiments disclosed herein. As used in the specification and in the claims, the singular form of “a”, “an”, and “the” include plural referents unless the context clearly dictates otherwise. In addition, as used in the specification and the claims, the term “or” means “and/or” unless the context clearly dictates otherwise. It should also be appreciated that some of the components and features discussed herein may be discussed in connection with only one (singular) of such components, and that additional like components which may be disclosed herein may not be discussed in detail for the sake of reducing redundancy.

[0014] Other aspects, features, and advantages of the present patent application will become apparent from the following detailed description, the accompanying drawings, and the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Various embodiments are disclosed, by way of example only, with reference to the accompanying schematic drawings in which corresponding reference symbols indicate corresponding parts, in which

[0016] FIG. 1 shows a cross-sectional view and a perspective view of a vehicle member assembly in accordance with an embodiment of the present patent application, wherein the vehicle member assembly includes steel beam portions, the beam portions are connected to each other using trim edge laser weld joints, the connected beam portions comprise a pair of generally hollow longitudinal regions separated by a wall portion of one of the beam portions; [0017] FIG. 2 shows a cross-sectional view and a perspective view of another vehicle member assembly in accordance with another embodiment of the present patent application, wherein the vehicle member assembly includes steel beam portions, the beam portions are connected to each other using trim edge laser weld joints, the connected beam portions comprise three generally hollow longitudinal regions separated by wall portions of one of the beam portions;

[0018] FIG. 3 shows a cross-sectional view and a perspective view of yet another vehicle member assembly in accordance with yet another embodiment of the present patent application, wherein the vehicle member assembly includes steel and trim edge laser weld joints, the vehicle member assembly comprises two generally hollow longitudinal regions separated by a wall portion;

[0019] FIGS. 4 A and 4B show a cross-sectional view and a perspective view, respectively, of a closed cross-section beam portion of the vehicle member assembly in accordance with an embodiment of the present patent application;

[0020] FIG. 5 shows a method of forming the closed cross-section beam portion of the vehicle member assembly in accordance with an embodiment of the present patent application; [0021] FIGS. 6 A and 6B show a cross-sectional view and a perspective view, respectively, of an open-section beam portion of the vehicle member assembly in accordance with an embodiment of the present patent application;

[0022] FIG. 7 shows a method of forming the open-section beam portion of the vehicle member assembly in accordance with an embodiment of the present patent application;

[0023] FIG. 8 shows a method of forming the open-section beam portion of the vehicle member assembly in accordance with another embodiment of the present patent application;

[0024] FIG. 9 shows a system for forming and inspecting the vehicle member assembly in accordance with an embodiment of the present patent application;

[0025] FIG. 10 shows a system for forming and inspecting the vehicle member assembly in accordance with another embodiment of the present patent application;

[0026] FIG. 11 shows a comparison of a master weld data, an inspection target weld data and an inspection result based on the comparison in accordance with an embodiment of the present patent application; [0027] FIG. 12 shows a side by side comparison of the weld and the inspection result based on the comparison of the master weld data and the inspection target weld data in accordance with an embodiment of the present patent application; and

[0028] FIG. 13 shows a cross-sectional view and a perspective view of a prior art galvanized multi-tubular vehicle beam.

DETAILED DESCRIPTION OF THE DRAWINGS

[0029] FIG. 1 shows a vehicle member assembly 100 of the present patent application. The vehicle member assembly 100 comprises a closed cross-section beam portion 102, at least one open-section beam portion 104, and trim edge laser weld joints 108, 110. The closed crosssection beam portion 102 comprises steel. The open-section beam portion 104 comprises steel. The open-section beam portion 104 has a generally U-shaped configuration. The open-section beam portion 104 has a pair of opposing, spaced legs 112. The trim edge laser weld joints 108, 110 connect the pair of legs 112 of the open-section beam portion 104 to opposite sides 114, 116 of the closed cross-section beam portion 102. The connected closed-section beam portion and open-section beam portion provide the vehicle member assembly 100 that comprises a pair of generally hollow longitudinal regions 118, 120 separated by a wall portion 122 of the closed cross-section beam portion 102.

[0030] In one embodiment, the steel comprises coated steel or uncoated steel. In another embodiment, the steel comprises galvanized coated steel or ungalvanized steel. In yet another embodiment, the steel comprises hot stamped steel. In yet another embodiment, the vehicle member assembly may be formed using non-ferrous aluminum material (i.e., instead of steel).

[0031] The vehicle member assembly 100 may be used for body and/or chassis components of a vehicle. The vehicle member assembly 100 may be used as rocker members, body in white (BIW) rocker assemblies, bumper beams, or body cross members of the vehicle. The vehicle member assembly 100 may be configured to withstand the tests for impact energy management and absorption and/or to meet to crash and safety requirements.

[0032] FIGS. 4 A and 4B show a cross-sectional view and a perspective view, respectively, of the closed cross-section beam portion 102. The closed cross-section beam portion 102 generally includes the two opposite sides 114, 116 and two opposite wall portions 122 and 123. In one embodiment, the two opposite sides 114, 116 are smaller (in dimension) than the two opposite wall portions 122 and 123. In another embodiment, the two opposite sides 114, 116 have the same dimension as the two opposite wall portions 122 and 123. [0033] The closed cross-section beam portion 102 may include a substantially tubular cross-sectional configuration. The closed cross-section beam portion 102 may include a substantially hollow configuration. The closed cross-section beam portion 102 may include a substantially circular, rectangular or square shaped tubular cross-sectional configuration. The closed cross-section beam portion 102 may include other shaped tubular cross-sectional configuration. The closed cross-section beam portion 102 may have four rounded comer portions. The rounded comer portions are optional.

[0034] The closed cross-section beam portion 102 may extend along a longitudinal axis L-L. The closed cross-section beam portion 102 may also include a center transverse axis CT- CT that is perpendicular to the longitudinal axis L-L and is disposed at a central portion of the closed cross-section beam portion 102. The closed cross-section beam portion 102 is a roll- formed member having ends thereof mating so as to provide a substantially continuous inner and outer surfaces. The mating ends of the closed cross-section beam portion 102 are welded together, for example, using an electric resistance seam welding or other welding procedures. [0035] FIG. 5 shows a method 500 of forming the closed cross-section beam portion 102 of the vehicle member assembly 100. As shown in FIG. 5, the closed cross-section beam portion 102 may be manufactured by roll forming a galvanized sheet metal, such as uncoiling from a roll. Roll forming generally is a type of rolling involving the continuous bending of a long strip of sheet metal (e.g., coiled steel) into a desired cross-sectional shaped configuration. [0036] The method 500 of forming the closed cross-section beam portion 102 includes uncoiling 502 of the coil 508 of the galvanic coated steel sheet metal and flattening 504 the sheet metal 506. That is, the coil 508 of the sheet metal 506 may be loaded onto an uncoiler (e.g., a single or a double uncoiler) and then fed through a flattener to straighten/flatten the sheet metal 506. These pre-processing steps, performed before roll forming procedure 510, may be optional.

[0037] The method 500 also includes the roll forming procedure 510 in which the flattened sheet metal 506 is progressively shaped. A roll forming system 512 may include a plurality of pairs of roller die stands 514, 516, 518, 520. The roll forming system 512 is individually or gang driven to force the ribbon of sheet metal 506 through the rollers 514, 516, 518, 520 that gradually shape the sheet metal 506 to the desired cross-sectional shaped configuration. For example, the roll-formed closed cross-section beam portion 102 has mating ends.

[0038] The method 500 further includes joining procedure 522 in which the mating ends of the roll-formed closed cross-section beam portion 102 are welded together, for example, using an electric resistance seam welding or other welding procedures. The weld seam may be oriented based on crush pattern or load path to the roll-formed closed cross-section beam portion 102. The method 500 may also include a calibration procedure 524, and a cutting procedure 526 in which the roll-formed closed cross-section beam portions 102 are cut to desired lengths. For example, the calibration procedure may include calibration of a section. The calibration procedure includes a sizing/forming operation/procedure that is configured to achieve dimensions as per drawing or 3D CAD specification.

[0039] Referring to FIG. 5, the closed cross-section beam portion 102 may be manufactured with conventional high-speed roll form process followed by electric resistance seam weld. This process can be done with much faster speed than the laser weld.

[0040] FIGS. 6 A and 6B show a cross-sectional view and a perspective view, respectively, of the open-section beam portion 104. The open-section beam portion 104 generally includes two legs 112 and a wall portion 127 perpendicular to and connecting the legs 112. The open-section beam portion 104 may include a substantially rectangular U-shaped configuration. In one embodiment, as illustrated in FIGS. 1 and 2, the two legs 112 may have same length/height. In another embodiment, the two legs 112 may have different lengths/heights. The open-section beam portion 104 may have two rounded corner portions (i.e., at the intersections between the wall portion 127 and the two legs 112). The rounded corner portions are optional.

[0041] The open-section beam portion 104 may extend along the longitudinal axis L- L. The legs 112 of the open-section beam portion 104 are spaced apart by a distance D such that the inner surfaces 128 of the legs 112 of the open-section beam portion 104 engage outer surfaces 130 of the sides 114, 116 of the closed cross-section beam portion 102 when the opensection beam portion 104 and the closed cross-section beam portion 102 are connected to each other. The legs 112 of the open-section beam portion 104 are disposed in overlapping configuration with the opposite sides 114, 116 of the closed cross-section beam portion 102. When the open-section beam portion 104 and the closed cross-section beam portion 102 are connected to each other, the ends of the legs 112 are disposed below the center longitudinal axis CT-CT.

[0042] The open-section beam portion 104 includes a roll-formed member as discussed with respect to FIG. 7. The open-section beam portion 104 includes a hot/cold stamped member as discussed with respect to FIG. 8.

[0043] In one embodiment, as shown in FIG. 7, the open-section beam portion 104 may be manufactured by roll forming a galvanized coated steel sheet metal, such as uncoiling from a roll. FIG. 7 shows a method 700 of forming the open-section beam portion 104 of the vehicle member assembly 100. The method 700 of forming the open-section beam portion 104 may include uncoiling of the coil of the sheet metal 706 and flattening the sheet metal 706. That is, the coil of the sheet metal 706 may be loaded onto an uncoiler (e.g., a single or a double uncoiler) and then fed through a flattener to straighten/flatten the sheet metal 706. These pre-processing steps, performed before roll forming procedure 710, may be optional.

[0044] The method 700 also includes the roll forming procedure 710 in which the flattened sheet metal 706 is progressively shaped. A roll forming system 712 may include a plurality of pairs of roller die stands 714, 716, 718. The roll forming system 712 is individually or gang driven to force the ribbon of sheet metal 706 through the rollers 714, 716, 718 that gradually shape the sheet metal 706 to the desired cross-sectional shaped configuration. The method 700 may also include a cutting procedure in which the roll-formed open-section beam portion 104 are cut to desired lengths.

[0045] In one embodiment, as shown in FIG. 8, the open-section beam portion 104 may be manufactured by stamping. In one embodiment, as shown in FIG. 8, the open-section beam portion 104 may be manufactured by hot stamping. In another embodiment, the open-section beam portion 104 may be manufactured by cold stamping. FIG. 8 shows a method 800 of forming the open-section beam portion 104 of the vehicle member assembly 100. The method 800 of forming the open-section beam portion 104 may include uncoiling procedure 801 in which a coil 804 of the galvanized coated steel sheet metal 806 is uncoiled, flattening procedure

802 in which the sheet metal 806 is flattened/straightened and blank sizing/cutting procedure

803 in which the sheet metal 806 is sized/cut into blanks 808 of desired dimensions.

[0046] The method 800 also includes heating procedure 810 in which the blank 808 is heated in a furnace 815 to a desired/predetermined temperature. The furnace 815 may be configured to heat multiple blanks 808 therein. The method 800 includes transferring procedure 812 in which the heated blank is transferred (using a transfer system 814) to a press 816. The method 800 includes forming and quenching procedure 818 in which the heated blank is formed and quenched in the press 816. The press 816 includes a cooling system 820 for quenching and includes a pair of dies 822 for forming the open-section beam portion 104 into the desired cross-sectional shaped configuration. The method 800 may include transferring (using a transfer system 824) the formed and quenched open-section beam portion 104 for further cooling and/or further processing.

[0047] As shown in the illustrated embodiment of FIG. 1, the vehicle member assembly 100 includes a single open-section beam portion 104 that is connected to the closed cross- section beam portion 102. Although the single open-section beam portion 104 of FIG. 1 is shown to be positioned below the closed cross-section beam portion 102 and is connected to the closed cross-section beam portion 102 from below the closed cross-section beam portion 102, in another embodiment, the single open-section beam portion 104 may be positioned above the closed cross-section beam portion 102 and is connected to the closed cross-section beam portion 102 from above the closed cross-section beam portion 102.

[0048] As shown in the illustrated embodiment of FIG. 1, the pair of legs 112 of the open-section beam portion 104 are connected to the opposite sides 114, 116 of the closed crosssection beam portion 102 such that the vehicle member assembly 100 includes the pair of generally hollow longitudinal regions separated by the wall portion 122 or 123 of the closed cross-section beam portion 102. The hollow longitudinal regions are disposed one on top/bottom of another arrangement.

[0049] In another embodiment, the pair of legs 112 of the open-section beam portion 104 may be connected to the opposite walls 122, 123 of the closed cross-section beam portion 102 such that the vehicle member assembly 100 includes the pair of generally hollow longitudinal regions separated by the side 114 or 116 of the closed cross-section beam portion 102. The hollow longitudinal regions are disposed side by side arrangement.

[0050] In one embodiment, as shown in FIG. 2, the at least one open-section beam portion includes two open-section beam portions 203 and 204. That is, the vehicle member assembly 200 includes the two open-section beam portions 203 and 204 and the open-section beam portion 202. The vehicle member assembly 200 in FIG. 2 includes two open-section beam portions 203, 204 that are connected to the closed cross-section beam portion 202.

[0051] The two open-section beam portions 203, 204 include the lower open-section beam portion 204 extending along the longitudinal axis L-L and is positioned below the closed cross-section beam portion 202 such that the U-shaped configuration of the lower open-section beam portion 204 is facing (the wall portion 222 of) the closed cross-section beam portion 202 and the upper open-section beam portion 203 extending along the longitudinal axis L-L and positioned above the closed cross-section beam portion 202 such that the U-shaped configuration of the upper open-section beam portion 203 is facing (the wall portion 223 of) the closed cross-section beam portion 202.

[0052] The lower and upper open-section beam portions 204, 203 are identical to each other in size and shaped configuration. Although, in other embodiments as discussed in detail throughout the present patent application, the lower and upper open-section beam portions 204, 203 may have different sizes and shaped configurations. [0053] The lower and upper open-section beam portions 204, 203 are identical (in the shaped configuration) to the open-section beam portion 104 (described in detail in FIG. 1) and, hence, the shaped configurations of the lower and upper open-section beam portions 204, 203 are not discussed in detail here. For example, the lower open-section beam portion 204 includes two legs 212 and wall portion 227 perpendicular to and connecting the legs 212, while the upper open-section beam portion 203 includes two legs 213 and wall portion 229 perpendicular to and connecting the legs 213. Inner surfaces 228 of the legs 212 of the lower open-section beam portion 204 engage outer surfaces 230 of the sides 214, 216 of the closed cross-section beam portion 202 when the lower open-section beam portion 204 and the closed cross-section beam portion 202 are connected to each other. Inner surfaces 231 of the legs 213 of the upper open-section beam portion 203 engage outer surfaces 230 of the sides 214, 216 of the closed cross-section beam portion 202 when the upper open-section beam portion 203 and the closed cross-section beam portion 202 are connected to each other. The trim edge laser weld joints 208, 210 are formed along respective trim edges 232, 234 of the pair of legs 212 of the lower open-section beam portion 204, while trim edge laser weld joints 209, 211 are formed along respective trim edges 236, 238 of the pair of legs 213 of the upper open-section beam portion 203.

[0054] As shown in the illustrated embodiment of FIG. 2, the pair of legs 212 of the open-section beam portion 204 and the pair of legs 213 of the open-section beam portion 203 are connected to the opposite sides 214, 216 of the closed cross-section beam portion 202 such that the vehicle member assembly 200 includes generally hollow longitudinal regions 218, 219, 220 separated by the wall portions 222, 223 of the closed cross-section beam portion 202. The hollow longitudinal regions are disposed one on top/bottom of another arrangement. In another embodiment, the pair of legs 212 of the open-section beam portion 204 and the pair of legs 213 of the open-section beam portion 203 are connected to the opposite wall portions 222, 223 of the closed cross-section beam portion 202 such that the vehicle member assembly 200 includes generally hollow longitudinal regions separated by the opposite sides 214, 216 of the closed cross-section beam portion 202. The hollow longitudinal regions are disposed side by side arrangement.

[0055] The trim edge weld may interchangeably referred to as an edge weld. The edge weld is easier to inspect than an overlap weld used in the prior art systems. The edge weld can be easily verified. For example, the edge weld that is at least in contact with the lower part over the entire weld length can be easily verified. [0056] A small portion of the weld material in the trim edge weld may be in between the surfaces but, by large, the weld material in the trim edge weld is exposed to the environment. The weld material in the trim edge weld is configured to connect an edge surface (e.g., ES in FIGS. 1-3) to a side surface (SS in FIGS. 1-3).

[0057] Referring to FIG. 1, the trim edge laser weld joints 108, 110 are formed along respective trim edges 132, 134 of the pair of legs 112 of the open-section beam portion 104. The legs 112 are arranged overlapping with the side walls 114, 116 of the closed cross-section beam portion 102. The trim edge weld joints 108, 110 are then formed between the end faces of the respective trim edges 132, 134 of the pair of legs 112 of the open-section beam portion 104 and the side walls 114, 116 of the closed cross-section beam portion 102.

[0058] The vehicle member assembly 100 in FIG. 1 includes two trim edge laser weld joints 108, 110 connecting the trim edges 132, 134 of the pair of legs 112 of the open-section beam portion 104 to the closed cross-section beam portion 102. The trim edge laser weld joints 108, 110 are disposed in-line, along an axis Tl-Tl that is perpendicular to the longitudinal axis L-L, with each other. The axis Tl-Tl is parallel to and is disposed below the center transverse axis CT-CT. In another embodiment, the trim edge laser weld joints may be disposed in-line with each other and may be disposed along (or above) the center transverse axis CT-CT.

[0059] When the open-section beam portion 104 is positioned above and is connected to the closed cross-section beam portion 102 from above, then the axis (along which the trim edge laser weld joints are disposed in-line with each other) is parallel to and is disposed above the center transverse axis CT-CT. In another embodiment, the trim edge laser weld joints may be disposed in-line with each other and may be disposed along (or below) the center transverse axis CT-CT.

[0060] The vehicle member assembly 200 in FIG. 2 includes four trim edge laser weld joints, two trim edge laser weld joints 208, 210 connecting the trim edges 232, 234 of the pair of legs 212 of the open-section beam portion 204 to the closed cross-section beam portion 202 and two trim edge laser weld joints 209, 211 connecting the trim edges 236, 238 of the pair of legs 213 of the open-section beam portion 203 to the closed cross-section beam portion 202.

[0061] In one embodiment, when the trim edges of the pair of legs of the open-section beam portion are connected to the sides of the closed cross-section beam portion, the trim edge laser weld joints are formed the sides of the closed cross-section beam portion. In another embodiment, when the trim edges of the pair of legs of the open-section beam portion to the walls of the closed cross-section beam portion, the trim edge laser weld joints are formed the walls of the closed cross-section beam portion. [0062] The lower open-section beam portion 204 of the vehicle member assembly 200 of FIG. 2 is connected to the closed cross-section beam portion 202 using lower trim edge laser weld joints 208, 210 that are disposed in-line, along a lower axis Tl-Tl that is perpendicular to the longitudinal axis L-L, with each other. The upper open-section beam portion 203 is connected to the closed cross-section beam portion 202 using two trim edge laser weld joints 209, 211 that are disposed in-line, along an upper axis T2-T2 that is perpendicular to the longitudinal axis L-L, with each other. The upper and lower axes T2-T2 and Tl-Tl are referred to as upper and lower transverse axes. The upper axis T2-T2 and the lower axis Tl-Tl are parallel and spaced apart from each other. For example, the lower axis Tl-Tl is parallel to and positioned below the center transverse axis CT-CT and the upper axis T2-T2 is parallel to and positioned above the center transverse axis CT-CT. In the illustrated embodiment, the lower axis Tl-Tl and the upper axis T2-T2 are parallel to and positioned equidistantly either above or below the center transverse axis CT-CT.

[0063] The connected closed-section beam portion and open-section beam portion provide the vehicle member assembly 200 that comprises three generally hollow longitudinal regions 218, 220, 219 separated by wall portions 222 and 223 of the closed cross-section beam portion 202. The closed cross-section beam portion 202 includes the generally hollow longitudinal region 218. The generally hollow longitudinal region 218 of the closed crosssection beam portion 202 is separated from the generally hollow longitudinal region 219 of the upper open-section beam portion 203 by the wall portion 223 of the closed cross-section beam portion 202. The generally hollow longitudinal region 218 of the closed cross-section beam portion 202 is separated from the generally hollow longitudinal region 220 of the lower opensection beam portion 204 by the wall portion 222 of the closed cross-section beam portion 202. [0064] FIG. 3 shows a cross-sectional view and a perspective view of yet another vehicle member assembly 300.

[0065] As shown in FIG. 3, the vehicle member assembly 300 comprises a single metal sheet roll 301 formed to form two adjacent beam portions 303 and 305. The two adjacent beam portions 303 and 305 provide the vehicle member assembly 300. The vehicle member assembly 300 includes a pair of generally hollow longitudinal regions 318 and 320 separated by a common central wall portion 322. The common central wall portion 322 includes bends 307, 309 at opposite ends 311, 313 thereof transitioning into a pair of first side walls 351 and 353. [0066] Each first side wall 351 or 353 constitutes one wall for a respective one of the beams 303 and 305. Each beam 303 and 305 includes an opposing second side wall 315 and 317 that is opposite the first side wall 351 and 353. For each of the beams 303 and 305, the second side wall 315 and 317 (a) contacts and overlaps the first side wall 351 and 353 of the other of the beams 303 and 305, and (b) has a terminal edge ES (or 334, 332) terminating at a location along the first side wall 351 and 353 of the other of the beams 303 and 305. A trim edge laser weld joint 308, 310 connecting the terminal edge ES (or 334, 332) of each of the second side walls 315 and 317 to the contacted first side wall 351 and 353 of the other beam 303, 305 at the location along the first side wall 351 and 353. The vehicle member assembly 300 further comprises a pair end walls EWi, ED2 connecting each first side wall 351 and 353 to the opposing second side wall 315 and 317.

[0067] The terminal edge ES may be interchangeably referred to as a terminal end, an end surface or an edge surface. The location (i.e., along the opposing first side wall 351 and 353 at which the terminal edge ES of each second side wall 315 and 317 are connected) may be interchangeably referred to as a side surface SS.

[0068] In one embodiment, the metal sheet includes steel. In one embodiment, the steel comprises coated steel or uncoated steel. In another embodiment, the steel comprises galvanized coated steel or ungalvanized steel. In yet another embodiment, the steel comprises hot stamped steel. In another embodiment, the metal sheet includes non-ferrous material, e.g., aluminum.

[0069] A method of forming the vehicle member assembly 300 is also provided. The method comprises roll forming the single metal sheet 301 to form two adjacent beam portions 303, 305. The two adjacent beam portions 303, 305 provide the vehicle member assembly 300 with the pair of generally hollow longitudinal regions 318, 320 separated by the common central wall portion 322. The common central wall portion 322 includes bends 307, 309 at opposite ends 311, 313 thereof transitioning into the pair of first side walls 351, 353. Each first side wall 351, 353 constitute one wall for a respective one of the beam portions 303, 305. Each beam portion 303, 305 comprises an opposing second side wall 315, 317 being opposite the first side wall 351, 353. For each of the beam portions 303, 305, the second side wall 315, 317 (a) contacts and overlaps the first side wall 351, 353 of the other of the beam portions 303, 305 and (b) has a terminal edge ES (or 334, 332) terminating at a location along the first side wall 351, 353 of the other of the beam portions 303, 305. The method also includes connecting by trim edge welding (e.g., trim edge laser weld joints 308, 310), the terminal edge ES (or 334, 332) of each of the second side walls 315, 317 to the contacted first side wall 351, 353 of the other beam portion 303, 305 at the location along the first side wall 351, 353. [0070] The vehicle member assembly 300 includes steel and trim edge laser weld joints 308, 310. The vehicle member assembly 300 comprises the two generally hollow longitudinal regions 318, 320 separated by the wall portion 322.

[0071] Unlike the embodiments of FIGS. 1 and 2, the vehicle member assembly 300 does not include a separate closed cross-section beam portion and one or more separate opensection beam portions that are connected to each other using trim edge laser weld joints. Instead, the vehicle member assembly 300 includes a single metal sheet that is roll formed into the desired cross-sectional shaped configuration. The ends 332, 334 of the final roll-formed cross- sectional shaped configuration are disposed in overlapping configuration with respective adjacent portions 351, 353 and are connected to the respective adjacent portions 351, 353 using trim edge laser weld joints 308, 310.

[0072] Unlike the ‘ 114 Patent in which the laser lap welds are used, the vehicle member assembly 300 uses trim edge laser weld joints for at least the reasons discussed in detail below. [0073] As trim edge laser welding is used (compared to the prior art’ s laser lap welding), the system of the present patent application is configured to reduce component mass by reducing metal overlap. Automotive designers always balance the conflicting requirements for minimizing the weight of the vehicle to maximize fuel economy, and maximizing vehicle strength and stiffness for improved vehicle dynamic behavior and passenger safety. The laser trim edge weld minimizes mass by reducing metal overlap that is required to enable lap weld. This can be a significant mass savings for longer length vehicle components such as rocker, door rings, long rails etc. Replacing laser lap weld with laser trim edge weld also leads to reduction lap weld trim material or two part overlap, for component such as rocker or body cross members. This will be significant mass saving.

[0074] Further, replacing lap weld with laser trim edge weld would eliminate additional pre-process like scarfing, protrusion required to vent zinc oxide gases produced during galvanic coated laser weld parts.

[0075] The trim edge laser weld may also be interchangeably referred to as fillet weld configuration. The trim edge laser weld has a lower tendency to trap zinc oxide gases when welding zinc coated steels, resulting in fewer weld blowouts caused by escaping zinc oxide fumes. A similar argument may be used for blowouts caused by residual oils or other surface contaminants.

[0076] The laser trim edge weld that replaces laser lap weld for the galvanic coated component also improves weld joint quality and weld penetration with 100% in process weld inspection. [0077] In process quality confirmation check feasibilities are a great advantage of the laser edge trim weld of the present patent application as the laser trim edge weld of the present patent application has in process 100% weld quality checks. The 100% in process weld quality checks are introduced during laser weld for repeatability or product quality. Weld quality issues with galvanic coating such as blow holes, gas inclusions, reduced or no weld penetration eliminated by using the laser trim edge weld. The present patent application also improves productivity and eliminates scrap due to cutting and etching quality checks with the laser lap weld. Weld inspection is also easier for a fillet configuration of the laser trim edge weld than for a lap weld, as the lap weld surface does not give any indication on the extent of fusion to the inner sheet.

[0078] By converting one single closed loop section to two pieces, the open-section beam portion 104 provides shape flexibility for load carrying capability and manufacturing process. In terms of design, gauge, material, along with section modulus may be varied to meet different strength requirements along the length of the open-section beam portion 104, 203, 204. Complex shape or sections along the length may be produced by using alternate manufacturing process such as hot stamping (as described with respect to FIG. 8).

[0079] In the present patent application, replacing a single closed form complex cross- sectional shaped configuration with tube and open section roll form enables flexibility to reduce gauge, use alternate low cost material based to meet different section force or energy absorption at various body and chassis components of the vehicle. The system of the present patent application also enables complex single void and multi-void closed sections by combining one or more formed parts (closed and open section) to meet different section force or energy absorption for various location in a body and chassis structure of a vehicle.

[0080] In one embodiment, the material of the closed cross-section beam portion 102 and the material of the open-section beam portion 104 are the same. In another embodiment, the material of the closed cross-section beam portion 102 and the material of the open-section beam portion 104 are different.

[0081] In yet another embodiment, as shown in FIG. 2, the vehicle member assembly 200 may include two open-section beam portions 203, 204 and the closed cross-section beam portion 202. In one embodiment, the materials of the two open-section beam portions 203, 204 and the material of the closed cross-section beam portion 202 are the same. In another embodiment, the materials of the two open-section beam portions 203, 204 and the material of the closed cross-section beam portion 202 may be different. That is, the material of the two open-section beam portions 203, 204 are same but may be same as or different than the material of the closed cross-section beam portion 202. In yet another embodiment, the materials of the two open-section beam portions 203, 204 are different but may be same as or different than the material of the closed cross-section beam portion 202. The vehicle member assembly 200 may be made from a single material, two different materials or three different materials.

[0082] The material used for forming the closed cross-section beam portion 102, 202 and the material used for the open-section beam portion 104, 203, 204 may include steel with galvanic coating thereon, martensite steel with galvanic coating thereon, Ultra-High Strength Steel (UHSS) with galvanic coating thereon, High-strength low-alloy (HSLA) steel with galvanic coating thereon, cold rolled steel with galvanic coating thereon or cold rolled martensitic steel with galvanic coating thereon. For example, in one embodiment, the material may include CR1500T/1200Y martensite material with galvanic coating thereon. That is, CR1500T/1200Y includes Grade MS1500 Martensitic Steel either in sheet or coil form.

[0083] The material used for forming the closed cross-section beam portion 102, 202 may include aluminum material, aluminum alloy material, or aluminum -based material. The material used for the open-section beam portion 104, 203, 204 may include aluminum material, aluminum alloy material, or aluminum -based material.

[0084] For example, the closed cross-section beam portion 102, 202 made of one material may be joined with the open-section beam portion 104, 203, 204 made of a different material.

[0085] In one embodiment, the closed cross-section beam portion 102, 202 made of one of aluminum material, aluminum alloy material, or aluminum-based material, steel with galvanic coating thereon, martensite steel with galvanic coating thereon, Ultra-High Strength Steel (UHSS) with galvanic coating thereon, High-strength low-alloy (HSLA) steel with galvanic coating thereon, cold rolled steel with galvanic coating thereon or cold rolled martensitic steel with galvanic coating thereon, CR1500T/1200Y martensite material with galvanic coating thereon may be joined with the open-section beam portion 104, 203, 204 made of other of the aluminum material, aluminum alloy material, or aluminum-based material, steel with galvanic coating thereon, martensite steel with galvanic coating thereon, Ultra-High Strength Steel (UHSS) with galvanic coating thereon, High-strength low-alloy (HSLA) steel with galvanic coating thereon, cold rolled steel with galvanic coating thereon or cold rolled martensitic steel with galvanic coating thereon.

[0086] The closed cross-section beam portion 102, 202 and the open-section beam portion 104, 203, 204 may be joined to each other using alternate joining methods such as structural bonding, fasteners, etc. as would be appreciated by a person of ordinary skill in the art.

[0087] The thickness of sheet metal is commonly specified by a traditional, non-linear measure known as its gauge. For example, the larger the gauge number, the thinner the sheet metal. In one embodiment, the gauge of the closed cross-section beam portion 102 and the gauge of the open-section beam portion 104 are the same. In another embodiment, the gauge of the closed cross-section beam portion 102 and the gauge of the open-section beam portion 104 are different.

[0088] As shown in FIG. 2, the vehicle member assembly 200 includes two opensection beam portions 203, 204 and the closed cross-section beam portion 202. In one embodiment, the gauges of the two open-section beam portions 203, 204 and the gauge of the closed cross-section beam portion 202 are the same. In another embodiment, the gauges of the two open-section beam portions 203, 204 and the gauge of the closed cross-section beam portion 202 are different. In another embodiment, the gauges of the two open-section beam portions 203, 204 are either same or different from each other. The vehicle member assembly 200 may be made from a single gauge, two different gauges or three different gauges.

[0089] In one embodiment, the widths of the sheet metal materials used to form the two open-section beam portions 203, 204 are the same. In another embodiment, the widths of the sheet metal materials used to form the two open-section beam portions 203, 204 are different. For example, when a larger width of the sheet metal material is used to form the open-section beam portion, the open-section beam portion may have longer legs and a deeper U-shaped configuration. When a smaller width of the sheet metal material is used to form the open-section beam portion, the open-section beam portion may have shorter legs and a shallower U-shaped configuration. For example, the lower open-section beam portion 204 may have one of the shallower U-shaped configuration and the deeper U-shaped configuration, while the upper open-section beam portion 203 may have the other of the shallower U-shaped configuration and the deeper U-shaped configuration.

[0090] In one embodiment, the two open-section beam portions 203, 204 of the vehicle member assembly 200 may have same section modulus. In one embodiment, the two opensection beam portions 203, 204 of the vehicle member assembly 200 may have different section modulus. In one embodiment, the two open-section beam portions 203, 204 of the vehicle member assembly 200 may have same shape and sized configurations. In another embodiment, the two open-section beam portions 203, 204 of the vehicle member assembly 200 may have different shaped and sized configurations.

[0091] The present patent application provides a method of forming the vehicle member assembly 100, 200. The method comprises roll forming a closed cross-section beam portion 102, 202. The closed cross-section beam portion 102, 202 comprises galvanized coated steel. The method also comprises roll forming at least one open-section beam portion 104, 204, 203 having a generally U-shaped configuration. The open-section beam portion 104, 204, 203 has a pair of opposing, spaced legs 112, 212, 213. The open-section beam portion 104, 204, 203 comprise galvanized coated steel. The method further comprises connecting the pair of legs 112, 212, 213 of the open-section beam portion 104, 204, 203 to opposite sides 114, 116, 214, 216 of the closed cross-section beam portion 102, 202 by trim edge laser welding. The connected closed-section beam portion and open-section beam portion providing the vehicle member assembly 100, 200 comprising a pair of generally hollow longitudinal regions 118, 120, 218, 219, 220 separated by a wall portion 122, 222, 223 of the closed cross-section beam portion 102, 202.

[0092] When welding/forming single void profile (as shown in FIGS. 1 and 3) or multivoid profile (as shown in FIG. 2), closed tube profile and open section(s) having roll form/stamped sheet-metal surfaces are disposed such that the laser weld head is configured to travel along 3D contours, and maintain an optimal pointing direction relative to the trim edges of the vehicle member assembly. Closed loop and open section(s) (e.g., two open sections in the case of the multi-void profile and one open section in the case of the single void profile) are clamped in an assembly fixture by using 3-2-1 principle to locate the component in all degrees of freedom. For example, the 3-2-1 principle generally states that the six locators are sufficient to restrict the required degree of freedom of any workpiece. In this, motion is restricted using clamps and locators. A three-pin base can restrict five motions and six pins restrict nine motions.

[0093] Based on the production volume, a special purpose assembly fixture(s) may be manufactured like roll form in process weld to reduce cycles time. Two components (closed tube profile and open section in the case of single void profile) or three components (closed tube profile and two open sections in the case of multi-void profile) are configured to be clamped by positive pressure to reduce any weld gap without deforming or damaging components.

[0094] Referring to FIGS. 9 and 10, the system 900 of the present patent application includes a three-dimensional (3D) laser camera 902, a laser beam delivery head 904, and a servo actuator 926. The servo actuator 926 may be configured such that it can receive signals from a controller 906 so as to control the weld head 904. The 3D laser camera may be interchangeably referred to as laser scanning camera, laser scanner, precision seam tracking system, inspection system, or laser camera. The laser beam delivery head may be interchangeably referred to as laser weld head and may be a high quality industry proven laser beam delivery head. In one embodiment, the laser scanner along with the laser weld head may be housed into one compact rugged package. The ability of the laser weld head to autofocus on the part surface is configured to reduce the requirement for detailed robot programming to follow every curve along the motion trajectory. The precision seam tracking system is configured to measure weld trim lateral location, surface height, etc., which in turn allows the weld system to adapt to part to part variations in real time.

[0095] For example, the elements of the weld head manipulator are controlled by the controller 906 which receives as input, a series of signals 908 including a signal from the laser camera 902 and then processes the information before transmitting a signal 910 to at least the weld head radial positioner, the weld head axial positioner, the weld head pivoter, and/or the wire delivery system. The weld head/torch 904 is then repositioned and reoriented continuously according to predetermined parameters of the controller 906 based on signals 908 from laser camera 902.

[0096] The system 900 includes a robot 914 with a base 916 and an arm 918. The laser weld head 904 as an end effector is attached to an arm end that is a tip portion of the arm 918. The robot 914 is operatively connected to and controlled by a robot controller 912. The laser weld head 904 is connected to a laser oscillator 920 via an optical fiber 922. Laser light generated by the laser oscillator 920 is supplied to the laser weld head 904 via the optical fiber 922. In illustrated embodiment, the laser oscillator 920 includes an Nd: YAG (neodymium- doped yttrium aluminum garnet) laser. The laser oscillator 920 may include various laser sources such as a fiber laser, a YAG laser, a CO 2 laser, and a semiconductor laser. The system 900 also includes an I/O 924 for synchronizing the laser oscillator 920, the robot controller 912, and the controller 906.

[0097] In one embodiment, the system 900 may include wire feed nozzles, shield gas nozzles, and a wire feeder. For example, the wire feeder of the system 900 is configured to control the speed of the feed wire during the welding procedure, the wire feed nozzles of the system 900 are configured to provide the feed wire during welding procedure, and the shield gas nozzles of the system 900 are configured to provide the shield gas during the welding procedure. [0098] In another embodiment, as shown in FIG. 10, the system 900 may also include a collision sensor/breakaway, an air knife, wire feed nozzles, shield gas nozzles, and a wire feeder (e.g., for aluminum welding). The functions of the shield gas nozzles, the wire feeder, and the wire feeder are described above. Welding for aluminum alloys like 6000 series require a filler alloy to the weld to prevent solidification cracking. An aluminum wire feeder from a MIG weld system may be adapted to the robot laser welder to enable welding of aluminum components. The system 900 may have other sub-systems, that may be obvious to a person of ordinary skill in the art, may facilitate the welding procedures.

[0099] The system 900 may include the user interface that is operatively connected to the controller 906 and is configured to display information (e.g., operational performance) of the system 900 to a user and/or solicit information as well as allow a user to enter data and/or other parameters of the system 900. The user interface may allow a user to modify one or more parameters of the system 900. For example, the user interface may be display such as a graphical display. The display may be a touch screen display or a liquid crystal display (LCD) display. Also, the user interface may include one or more buttons or other controls that allow a user to modify one or more parameters of the system 900. For example, the one or more buttons or other controls of the user interface may be operated by touch or tactile manipulation or mechanical type control.

[00100] The system of the present patent application uses trim edge laser weld along with three stage laser welding procedures so as to ensure 100% in process weld inspection. As shown in FIGS. 9 and 10, trim edge weld equipment has three stages.

[00101] In the first stage of the three stage laser welding procedures, the laser scanner is configured to perform real time trim edge laser tracking or scanning. This stage may also be referred to as seam tracking stage. The laser scanner 902 is configured to scan trim edge for its straightness variation along the length of component and send feedback signals from the controller 906 to the servo actuator 926. Based on the signals from the laser scanner 902, the servo actuator 926 is configured to adjust position and/or location of the laser weld head 904 to align with the trim edge. The trim edge laser scanner 902 may be located around 10 to 30 millimeters (mm) ahead of the laser weld head 904 and the servo actuator 926/the controller 906.

[00102] In the second stage, the laser welding head 904 and the servo actuator 926 are configured to control position of laser head’s laser delivery fiber 922, to control the collision sensor, to control wire feeder if wire feeding is necessary and/or to control shielding nozzles. [00103] In the last/third stage, the laser scanner 902 with the laser weld head 904 are configured to improve visual weld quality. For example, the laser scanner 902 with the laser weld head 904 are configured to produce good welds day after day even with the inherent variability common in manufacturing plants by determining the joining processes’ capabilities. The inspection system may help quantify what these variations are. After improving the process as much as possible, the inspection system is then used to monitor the ongoing quality.

[00104] In one embodiment, the laser weld inspection system may include the 3D laser camera, a two-dimensional (2D) color video camera, an industrial control unit/controller and an inspection software package. Referring to FIGS. 11 and 12, the laser weld inspection unit is configured to compare the master weld data 1101 with the target weld data 1102 and to determine/judge pass/fail (e.g., see inspection result 1104) based on the concordance rate. The concordance rate is a statistical measure of agreement and can be defined as the proportion of pairs of components that share a particular attribute, given that one of the components has that characteristic. The laser weld head in process weld inspection compares weld data with master data like CAD or math data. This helps to detect weld defects like pit, blow holes, chipping of bead, of line bead, over or under bead width, length, pin holes, under cut, weld spatters etc. This reduces production downtime by controlling or monitoring real time weld quality also reducing scrap rate. FIG. 12 shows one the weld defects/pits that are captured by in process weld inspection method.

[00105] Some of the details of the system 900 in FIGS. 9 and 10 (e.g., that covers the three stages of laser welding) are also described in detail in the research paper titled “Laser Welding of Hem Flange Joints,” by Robert Muller, presented at ICALEO 2000, October 2-5, 2000, Detroit MI and proceedings published by the Laser Institute of America, which is incorporated by reference herein in its entirety.

[00106] In one embodiment, the system 900 may be a MDL/E™ system, which is an intelligent high-speed and high-precision modular system for seam tracking and weld inspection in laser welding, manufactured by Servo-Robot. The system is configured to ensure the quality of the welds. The MDL/E™ system includes an intelligent modular laser welding system that integrates two high-precision 3D laser cameras and a high quality industrially proven laser beam delivery head (up to 30 kW) into a compact rugged package to perform realtime seam tracking, weld inspection, and process control. The seam tracking and adaptive process control of the MDL/E™ system provides, among other things, precise part to part variation measurement and adjustment of tool position in real-time; tracking of complex 2D and 3D trajectories with curve radius; closed loop servo-controlled high speed actuators to precisely correct the 3D trajectory according to join position, etc.

[00107] The present patent application is configured to provide an alternative geometry by simplifying cross-sectional shaped configuration (e.g., compared to the ‘ 144 Patent) for ease of manufacturing and repetitive to produce during mass production. The modified tubular plus open section design of the present patent application also enables increased speed of closed roll form section by replacing laser weld with electric resistance weld, and laser welding open section by achieving same crush/section performance as baseline design. The improved roll form and laser weld feasibility is provided, using the present patent application, for manufacturing team for mass production of tube and open U section.

[00108] Closed section in process roll form laser weld process requires two laser weld machines customized to specific section. The present patent application replaces in process or customized laser head station to stand alone laser weld station that can be used to laser weld other components. This helps for early return on investment.

[00109] As is generally known martensite material exhibits high spring back during roll form process. It will be challenging to run without frequent production stoppage to ensure no weld gap or tune weld gaps. The present patent application uses positive clamping to make sure there is no weld gap because of spring back issues. That is, influence of spring back and subsequently weld gap were reduced as the vehicle member assembly is s positively clamped outside roll form process.

[00110] The closed or open section geometry ensures acceptable weld quality without any additional preprocesses such as scarfing, protrusion to vent zinc oxide gases produced while burning galvanic coating. The use of trim edge laser weld along with three stage laser welding ensures 100% in process weld inspection. This helps to reduce production down time, and frequency destructive weld inspection testing. This also reduces scrap rate and helps to lower warranty issues due to poor weld quality. This further helps to gain customer confidence for the quality of the part.

[00111] By changing complex roll form section to two pieces, that is closed conventional roll form and open section (that is either roll form or hot stamped), provides same section strength to meet crash and safety requirements. Also, varied strengths requirements may be achieved by changing two component gauge, material, and open section forms.

[00112] By replacing closed roll form return on investment may be improved by using laser head to produce other laser weld components. The use of the laser trim edge weld provides weight saving by reducing part to part overlap for longer length components such has body in white (BIW) rocker assemblies, body cross member, long member, bumper beams, etc.

[00113] The present patent application uses laser trim edge welding to create joints 108,

110 between the closed tube 102 and one or more open sections 104. The closed tube 102 and the one or more open sections 104 have galvanized coating. The present patent application is configured to create a single void steel part/component or a multi-void steel parts/components (e.g., as shown in FIGS. 1-3) with multi laser trim edge welding of one or more formed parts from galvanized and non-galvanized sheet stock.

[00114] The present patent application and its various embodiments as described above uniquely address the observed, noted and researched findings and improve on the prior and current state of the art systems. The listed products, features and embodiments as described in the present patent application should not be considered as limiting in any way.

[00115] Although the present patent application has been described in detail for the purpose of illustration, it is to be understood that such detail is solely for that purpose and that the present patent application is not limited to the disclosed embodiments, but, on the contrary, is intended to cover modifications and equivalent arrangements that are within the spirit and scope of the appended claims. In addition, it is to be understood that the present patent application contemplates that, to the extent possible, one or more features of any embodiment can be combined with one or more features of any other embodiment.

[00116] The illustration of the embodiments of the present patent application should not be taken as restrictive in any way since a myriad of configurations and methods utilizing the present patent application can be realized from what has been disclosed or revealed in the present patent application. The systems, features and embodiments described in the present patent application should not be considered as limiting in any way. The illustrations are representative of possible construction and mechanical embodiments and methods to obtain the desired features. The location and/or the form of any minor design detail or the material specified in the present patent application can be changed and doing so will not be considered new material since the present patent application covers those executions in the broadest form. [00117] The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms “a,” “an,” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises,” “comprising,” “including,” and “having,” are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed.

[00118] When an element or layer is referred to as being “on,” “engaged to,” “connected to,” or “coupled to” another element or layer, it may be directly on, engaged, connected or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly engaged to,” “directly connected to,” or “directly coupled to” another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.

[00119] Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments.

[00120] Terms of degree such as “generally,” “substantially,” “approximately,” and “about” may be used herein when describing the relative positions, sizes, dimensions, or values of various elements, components, regions, layers and/or sections. These terms mean that such relative positions, sizes, dimensions, or values are within the defined range or comparison (e.g., equal or close to equal) with sufficient precision as would be understood by one of ordinary skill in the art in the context of the various elements, components, regions, layers and/or sections being described.

[00121] The foregoing illustrated embodiments have been provided to illustrate the structural and functional principles of the present patent application and are not intended to be limiting. To the contrary, the present patent application is intended to encompass all modifications, alterations and substitutions within the spirit and scope of the appended claims.

Claims

What is claimed is:

1. A vehicle member assembly comprising: a closed cross-section beam portion, the closed cross-section beam portion comprising steel; at least one open-section beam portion having a generally U-shaped configuration, the open-section beam portion having a pair of opposing, spaced legs, the open-section beam portion comprising steel; and trim edge laser weld joints connecting the pair of legs of the open-section beam portion to opposite sides of the closed cross-section beam portion, the connected closed-section beam portion and open-section beam portion providing the vehicle member assembly comprising a pair of generally hollow longitudinal regions separated by a wall portion of the closed cross-section beam portion.

2. The vehicle member assembly of claim 1, wherein the steel comprises coated steel or uncoated steel.

3. The vehicle member assembly of claim 1, wherein the steel comprises galvanized coated steel or ungalvanized steel.

4. The vehicle member assembly of claim 1, wherein the steel comprises hot stamped steel

5. The vehicle member assembly of claim 1, wherein the pair of legs of the open-section beam portion is disposed in overlapping configuration with the opposite sides of the closed cross-section beam portion.

6. The vehicle member assembly of claim 1, wherein the closed cross-section beam portion extends along a longitudinal axis, wherein the open-section beam portion extends along the longitudinal axis, and wherein the trim edge laser weld joints are disposed in-line, along an axis that is perpendicular to the longitudinal axis, with each other.

7. The vehicle member assembly of claim 1, wherein the closed cross-section beam portion includes a substantially tubular cross-sectional configuration.

8. The vehicle member assembly of claim 1, wherein the closed cross-section beam portion is a roll-formed member having ends thereof mating so as to provide a substantially continuous inner and outer surfaces.

9. The vehicle member assembly of claim 1, wherein the open-section beam portion includes a roll-formed member.

10. The vehicle member assembly of claim 1, wherein the open-section beam portion includes a hot stamped member.

11. The vehicle member assembly of claim 6, wherein the at least one open-section beam portion includes two open-section beam portions, and wherein the two open-section beam portions include a lower open-section beam portion extending along the longitudinal axis and is positioned below the closed cross-section beam portion such that the U-shaped configuration of the lower open-section beam portion is facing the wall portion of the closed cross-section beam portion and an upper open-section beam portion extending along the longitudinal axis and positioned above the closed cross-section beam portion such that the U-shaped configuration of the upper open-section beam portion is facing another wall portion of the closed cross-section beam portion.

12. The vehicle member assembly of claim 11, wherein the lower open-section beam portion is connected to the closed cross-section beam portion using lower trim edge laser weld joints that are disposed in-line, along a lower axis that is perpendicular to the longitudinal axis, with each other, wherein the upper open-section beam portion is connected to the closed cross-section beam portion using two trim edge laser weld joints that are disposed in-line, along an upper axis that is perpendicular to the longitudinal axis, with each other, and wherein the upper axis and the lower axis are parallel and spaced apart from each other.

13. The vehicle member assembly of claim 1, wherein the trim edge laser weld joints are formed along respective trim edges of the pair of legs of the open-section beam portion.

14. The vehicle member assembly of claim 1, wherein the at least one open-section beam portion is welded to the closed cross-section beam portion at areas along respective trim edges of the legs of the at least one open-section beam portion.

15. A method of forming a vehicle member assembly, the method comprising: roll forming a closed cross-section beam portion, the closed cross-section beam portion comprising steel; roll forming at least one open-section beam portion having a generally U-shaped configuration, the open-section beam portion having a pair of opposing, spaced legs, the opensection beam portion comprising steel; and connecting the pair of legs of the open-section beam portion to opposite sides of the closed cross-section beam portion by trim edge laser welding, the connected closed-section beam portion and open-section beam portion providing the vehicle member assembly comprising a pair of generally hollow longitudinal regions separated by a wall portion of the closed cross-section beam portion.

16. A vehicle member assembly comprising: a single metal sheet roll formed to form two adj cent beam portions, the two adj cent beam portions providing the vehicle member assembly with a pair of generally hollow longitudinal regions separated by a common central wall portion, the common central wall portion having bends at opposite ends thereof transitioning into a pair of first side walls, each first side wall constituting one wall for a respective one of the beam portions, each beam portion having an opposing second side wall being opposite the first side wall, wherein, for each of the beam portions, the second side wall (a) contacts and overlaps the first side wall of the other of the beam portions, and (b) has a terminal edge terminating at a location along the first side wall of the other of the beam portions; and a trim edge laser weld joint connecting the terminal edge of each of the second side walls to the contacted first side wall of the other beam portion at the location along the first side wall.

17. The vehicle member assembly of claim 16, further comprising a pair end walls connecting each first side wall to the opposing second side wall.

18. The vehicle member assembly of claim 16, wherein the metal sheet comprises coated steel or uncoated steel.

19. The vehicle member assembly of claim 16, wherein the metal sheet comprises galvanized coated steel or ungalvanized coated steel.

20. The vehicle member assembly of claim 16, wherein the metal sheet comprises hot stamped steel.

21. The vehicle member assembly of claim 16, wherein the metal sheet comprises aluminum.

22. A method of forming a vehicle member assembly, the method comprising: roll forming a single metal sheet to form two adjacent beam portions, the two adjacent beam portions providing the vehicle member assembly with a pair of generally hollow longitudinal regions separated by a common central wall portion, the common central wall portion having bends at opposite ends thereof transitioning into a pair of first side walls, each first side wall constituting one wall for a respective one of the beam portions, each beam portion having an opposing second side wall being opposite the first side wall, wherein, for each of the beam portions, the second side wall (a) contacts and overlaps the first side wall of the other of the beam portions, and (b) has a terminal edge terminating at a location along the first side wall of the other of the beam portions; and connecting by trim edge welding, the terminal edge of each of the second side walls to the contacted first side wall of the other beam portion at the location along the first side wall.